System and method for illuminating a semiconductor processing system

ABSTRACT

The present invention relates to illuminating an interior portion of a processing chamber in a semiconductor processing system. A light emitting diode is located in the chamber to illuminate the interior of the chamber to facilitate viewing the interior of the chamber.

This application claims the benefit of Provisional Application No. 60/199,480, filed Apr. 25, 2000.

TECHNICAL FIELD

The present invention relates generally to semiconductor processing and, more particularly, to a system and method for illuminating a semiconductor processing system.

BACKGROUND OF THE INVENTION

The tendency of semiconductor devices such as integrated circuits (IC) and large scale integrated circuits (LSIC) toward minuteness has rapidly progressed, and higher accuracy and efficiency have been required of apparatuses for manufacturing such semiconductor devices. Semiconductor integrated circuits undergo a variety of processing steps during manufacture, such as masking, resist coating, developing, etching, and deposition. In many of these steps, material is applied or removed from a substrate within a processing chamber having a controlled environment.

In order to remain competitive, manufacturers of semiconductor devices continually strive to improve production yields, while at the same time seeking to reduce associated manufacturing costs. As customers require larger quantities of semiconductor products, manufacturers increasingly seek equipment capable of operating efficiently for producing products commensurate with their customers' expectations. Because floor space is at a premium in most manufacturing facilities (due to the clean room environment necessary for fabrication of semiconductor devices), the manufacturers of semiconductor processing equipment have responded by producing semiconductor processing systems having vertically integrated processing units. One particular example of a vertically integrated semiconductor processing system is a coater/developer track system in which multiple coater and/or developer units are vertically stacked on top of each other, typically at the upper part of the track system.

SUMMARY OF THE INVENTION

The present invention relates to a system and method for illuminating a semiconductor processing system.

A light source, such as a light emitting diode (LED), is operatively associated with an enclosed chamber of a semiconductor processing system. The light source illuminates the interior of the chamber to facilitate visual inspection by a technician so as to, for example, assist in troubleshooting and/or other monitoring within the chamber. The light source may be a yellow wavelength light or any light color that will not expose substantially the resist.

One aspect of the present invention relates to a system for illuminating a semiconductor processing system. The system includes an enclosed processing chamber of the processing system having an interior. A light emitting diode is associated with the chamber for illuminating the interior of the chamber.

Another aspect of the present invention relates to a system for illuminating a semiconductor processing system. The system includes illumination means operatively associated with an interior of an enclosed processing chamber of the processing system for illuminating the interior of the chamber.

Another aspect of the present invention relates to a method for visibly illuminating an interior of an enclosed processing chamber in a semiconductor processing system. The method includes using a light emitting diode to illuminate the interior of the chamber to facilitate viewing the interior of the chamber.

To the accomplishment of the foregoing and related ends, the invention, then, comprises the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative aspects of the invention. These aspects are indicative, however, of but a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic block diagram of an enclosed chamber of a semiconductor processing system equipped with an illuminating device in accordance with the present invention;

FIG. 2 is side sectional view of a processing chamber equipped with an illuminating device in accordance with the present invention;

FIG. 3 is a sectional view taken along line 3—3 of the chamber of FIG. 2;

FIG. 4 is an isometric schematic illustration of a track system equipped with illuminating devices in accordance with the present invention;

FIG. 5 is a flow diagram illustrating a method of illuminating a processing chamber in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout.

FIG. 1 is a schematic block diagram of a system 100 for illuminating a semiconductor processing system 102 in accordance with the present invention. The system 100 includes an illuminating device 110 associated with an enclosed chamber 120 of the processing system 102. In particular, at least part of the illuminating device 110 is located within the interior of the chamber 120 for illuminating the contents of the chamber. The illuminating device 110 is connected to a controller 130 via a communications link 140 for controlling operation of the illuminating device.

The controller 130 may be located remote from the chamber 120, such as located at a console outside a clean room in which the processing system 102 is situated. Alternatively, the controller 130 may be integrally connected with the system 102 in which the chamber 120 is mounted. Depending on, for example, the location of the controller 130 relative to the system 102, the communications link 140 between the illuminating device 110 and the controller may be wired or wireless. The term “wired” as used herein is intended to include any physical communications link, including, for example, an electrically conducting cable and a fiber optical link. Similarly, the term “wireless” is intended to cover any form of communication that utilizes air as a transmission medium, including, for example, electromagnetic, optical, and acoustic forms of communication links. The communication over the link 140 may be analog or digital. In addition, the communications link 140 may be bidirectional, in which operation of the illuminating device 110 is both controlled and monitored by the associated controller 130. For example, the illuminating device 110 may be manually activated by a switch device (not shown) operatively connected to the controller 130. Alternatively, the illuminating device 110 may be activated automatically, such as in response to sensing equipment (not shown) associated with the chamber 120 indicating that one or more conditions of the chamber 120 are not within expected operating parameters. In such situations, the controller 130 also may activate a warning alarm to assist the technician in troubleshooting efforts.

By way of example, the system 102 of FIG. 1 is a track system in which semiconductor wafers are loaded into, processed, and unloaded. In the track system, the chamber 120 is a part of a processing unit, such as a coater, developer, heating unit, cooling unit, etc. Wafers are placed into the processing chamber 120 of the respective unit and subjected to various controlled processes, such as resist coating, developing, heating, and/or cooling. The illuminating device 110 provides a mechanism which facilitates visual inspection by a technician, such as for visually monitoring the progress and/or troubleshooting within the processing chamber 120.

FIGS. 2 and 3 illustrate a schematic illustration of a system 200 for illuminating a processing chamber 220 of a semiconductor processing system in accordance with the present invention. The chamber 220 is configured for receiving and processing a wafer 260 in a predefined manner. In particular, the chamber 220 is a cup or container, such as part of a processing unit (e.g., a coater or developer) of a track system. The chamber 220 has a generally cylindrical sidewall 262 which encloses a rotatable chuck 264 onto which the wafer 260 (or other substrate) is mounted for processing. The chuck 264 typically includes a vacuum system (not shown) for holding the wafer 260 on its surface during processing.

In a spin processing unit, for example, a nozzle (not shown) typically supplies a predetermined amount of viscous material (e.g., resist or solvent) onto the wafer 260. The chuck 264 and wafer 260 are then accelerated to and rotated at a certain speed, and centrifugal forces exerted on the viscous material cause the material to disperse over the surface of the wafer. It will be appreciated that, for purposes of the present invention, the features of the illuminating system 200 are applicable to all types of wafer processing units.

In accordance with the present invention, one or more illuminating devices, such as light emitting diodes (LEDs) 210 a, 210 b, 210 c, and 210 d (hereinafter collectively referred to as 210) are operatively associated with the chamber 220 for illuminating the interior of the chamber. While one LED 210 may be sufficient to illuminate the interior of the chamber 220, more than one LED may be employed to provide additional illumination for selected portions within the chamber 220. By way of example, the LEDs 210 a and 210 b are mounted to the bottom of the chamber 220 for emitting light to illuminate a lower portion of the chuck 264 and the mounting arrangement of the wafer 260 and chuck. The other LEDs 210 c and 210 d are, for example, mounted to the sidewall 262 near the upper end of the chamber 220 in a diametrically opposed manner. The LEDs 210 c and 210 d emit light to illuminate the interior of the chamber 220 and the upper surface of the wafer 260 and/or chuck 264. According to one aspect of the present invention, the LEDs do not increase substantially the temperature within the chamber 220, thereby maintaining the temperature uniformity therein.

The LEDs 210 usually are selected to provide light at a wavelength so as not expose photoresist material being employed (e.g., in a developer or coater unit). For example, yellow light may be employed when the photoresist being used is exposed in response to ultraviolet light. Because of their small size and unobtrusive positioning in the chamber 220, the LEDs 210 do not interfere with the processing environment of the chamber. In addition, the LEDs 210, when activated, dissipate relatively small amounts of heat (individually and collectively) so as not to adversely interact with or otherwise impact flammable chemicals which typically are used in various types of processing chambers 220. Accordingly, the LEDs 210 illuminate the interior of the chamber 220 to facilitate visual inspections while mitigating a fire hazard. Illumination of the chamber 220 may be enhanced by constructing the interior sidewall 262 of the chamber of an appropriate reflective material.

Similar to the example described with respect to FIG. 1, the LEDs 210 may be manually activated (e.g, by a technician) and/or may be automatically activated by a controller 230. It is to be appreciated that the illuminating system 200 also may operate without a controller 230. For example, the LEDs 210 may be activated or deactivated (e.g., ON or OFF) in response to the operating condition of an associated switch device or in response to the operating state of the processing system 202.

In the example of FIGS. 2-3, the controller 230 controls operation of the LEDs 210. The controller 230 is programmed to control and operate the LEDs 210 and other various components within the system 200 in order to carry out the various functions described herein. The manner in which the controller 230 can be programmed to carry out the functions relating to the present invention will be readily apparent to those having ordinary skill in the art based on the description provided herein. While the controller 230 is illustrated as being remote from the processing chamber 220, it is to be understood that the controller also may be integrated as part of the associated processing system 202 or implemented as a stand-alone controller.

In order to sense operating conditions of the chamber 220, sensors 292 are operatively connected with the chamber to sense various operating parameters thereof. The operative connection between the sensors 292 and the chamber 220 is schematically illustrated at 294. The sensors 292 may be integrated sensors of the associated processing system 202 which are used to sense operating conditions associated with the chamber 220. The sensors 292 also may include sensing equipment specifically configured to facilitate operation of the illuminating system 200. The sensors 292 provide sensor signals to the controller 230 indicative of the sensed operating conditions. The sensors 292 may be configured to sense a variety of operating conditions, such as, for example, light, temperature, pressure, vibration, rotation speed of the chuck 264, or any other condition useful in controlling the operation of the processing unit associated with the chamber 220.

The controller 230 controls operation of the LEDs 210 in response to the sensor signals. By way of example, the controller 230 may activate the LEDs 210 if the sensor signal indicates that an aspect of the process within chamber 220 is operating outside an expected operating parameter. The aspect of the system within the chamber 220 experiencing the potential problem is illuminated to facilitate its visual inspection for troubleshooting. The controller 230 also might activate an alarm or warning signal to alert the technician of a potential abnormal operating condition. In addition, the controller 230 may be programmed or configured to activate the LEDs 210 at selected times to assist the technician with a visual inspection of the internal operations of the chamber 220, such as at scheduled maintenance intervals.

The controller 230 also may be programmed to receive feedback related to the operation of the LEDs 210 (either directly from the LEDs or from one of the sensors 292). For example, the controller 230 might, based on feedback of the LEDs 210, adjust the intensity of each LED to maintain a desired intensity of light within the chamber 220. The controller 230 also may rapidly activate and deactivate the LEDs 210 in a strobe-light manner to help monitor and diagnose moving parts within the chamber 220 (e.g., chuck 264, nozzle arm).

It also may be desirable to selectively activate and deactivate different LEDs 210 at selected times according to the type of chamber 220 and/or the sensed operating conditions thereof. In a coater processing chamber, for example, LEDs 210 a and 210 c may be configured to emit light at a wavelength that matches the wavelength needed to expose photoresist (e.g., 157 nm, 193 nm, 248 nm, 365 nm, etc.) and LEDs 210 b and 210 d may be configured to emit light that does not expose the photoresist material. For example, one or more LEDs may be located within the chamber 220 which emit light having a wavelength which will expose the resist, while other LEDs may be employed in the chamber which emit light in the visible spectrum to provide illumination without exposing the resist. The controller 230 activates LEDs 210 b and 210 d at any time to facilitate viewing the interior of the chamber 220. However, the controller 230 limits activation of LEDs 210 a and 210 c to situations when no resist-coated wafer is within the chamber 220. This method of control enables the system to employ the LEDs 210 to perform a dual purpose, namely, illuminating the interior of the chamber 220 and cleaning by exposing remaining photoresist material within the chamber 220. The exposed photoresist is easily removed from the chamber 220.

A single LED 210 also may be configured to selectively emit light at two different wavelengths, such that the single LED provides a dual purpose. Specifically, the controller 230 may activate the single LED 210 to emit light at a first wavelength to expose remaining photoresist material in the chamber 220 (for cleaning purposes) and at a second wavelength to illuminate the contents of the chamber to facilitate visual inspection thereof. In cases where the LED is emitting an exposing light wavelength, the chamber cover should be closed so as to protect personnel from exposure to such wavelengths. In addition, with regard to negative resists, a solely illuminating wavelength LED system may be utilized, as may be desired.

The foregoing examples illustrate but a few approaches as to how one of ordinary skill in the art may program or otherwise configure the controller 230 to control the illuminating system 200 in accordance with the present invention. It is to be appreciated that many other control methodologies may be implemented in accordance with the present invention and that all such control methodologies are intended to fall within the scope of the appended claims.

FIG. 4 is a representative schematic illustration of a system 300 for illuminating a plurality of processing units of an exemplary semiconductor processing track system 302 in accordance with the present invention. The track system 302 includes a plurality of vertically stacked spin coater units 320 a, 320 b, 320 c (hereinafter collectively referred to as 320) and spin developer units 322 a, 322 b, 322 c (hereinafter collectively referred to as 322). Other processing units 324 and 326 may be provided for implementing other required processing steps within the track system 302. For example, unit 324 may be a baking unit (heater) and unit 326 may be a cooling unit (cooler) for selectively exposing a wafer to different controlled temperatures during the wafer fabrication process. Each of the chambers may include the illumination system described herein. With regard to the baking units, the illumination cover is adapted to withstand the elevated temperatures, whereas in the developer units, the illumination cover is adapted to withstand the various chemicals which may come in contact therewith.

The track system 302 includes receiving and sending sections 340 and 342, respectively, for storing cassettes 360 a, 360 b, 360 c, 360 d of wafers at different stages of the fabrication process. The track system 302 also includes several robotically actuated transport arms 370 a, 370 b (hereinafter collectively referred to as 370). Each arm 370 includes a tray having an upper surface for receiving a wafer. The arms 370 move along tracks 380 or paths for transporting wafers between the storage cassettes 360 and the processing units 320, 322, 324, and 326 of the system 302. Each of the processing units 320, 322, 324, 326 include a door through which the wafers are transported. While two arms 370 are illustrated in FIG. 4, it will be appreciated that several more arms may be used for moving wafers through the various parts of the coating and developing processes. Additional tracks also may be provided to facilitate wafer transport.

By way of example, the receiving section 340 includes one cassette 360 a which contains bare wafers to which a photoresist material is to be applied or coated in the coater units 320. The arms 370 transfer a wafer from the cassette 360 a to a coater unit 320 which coats a selected photoresist material onto the wafer surface. Another cassette 360 b stores resist-coated wafers that have been selectively exposed to radiation, such as during a photolithography process. The arms 370 transport a wafer from the cassette 360 b to a selected developer unit 322 which develops and/or removes the exposed photoresist, such as by application of a solvent. The sending section 342 includes cassettes 360 c and 360 d which store wafers after having been processed in the processing units 320 and 322. For example, cassette 360 c receives and stores resist-coated wafers from the coater units 320 and cassette 360 d receives and stores wafers after being processed in a developer unit 322.

The processing units 320, 322, 324, and 326 are located at the top part of the track system 302, which is enclosed by a housing 385 (illustrated in phantom for ease of illustration). The track system 302 also has a height, indicated at 384, which may be in excess of ten feet. While, under normal operating conditions, the track system 302 enables a manufacturer to increase production yields, the increased height has resulted in practical difficulties for semiconductor manufacturers. The processing units 320, 322, 324, and 326 include enclosed processing chambers (e.g., 120, 220 of FIGS. 1-3) which provide controlled environments for wafer processing and mitigating contamination caused by, for example, particulate material and/or unwanted light.

The ambient lighting in the room where the system 302 is situated usually is insufficient to view within the enclosure 385, especially the interior of the processing units 320, 322, 324, and 326. For example, in order to visually inspect interior parts of the system 302, such as when troubleshooting a potential abnormal operating condition, it may be necessary to remove panels of the system and/or to employ external sources of light in an effort to illuminate a selected internal part or parts of the system 302. External sources of light, however, often cast shadows on the very internal components that the technician wishes to inspect.

In accordance with the present invention, one or more illuminating devices, such as LEDs 310, are integrated into each processing unit 320, 322, 324, 326. In particular, the LEDs 310 are mounted in an enclosed chamber (e.g., 120, 220FIGS. 1-3) of each processing unit 320, 322, 324, 326 and housing 385 to facilitate viewing of internal system parts not easily visible by the technician. One or more additional LEDs 310 also are located within the housing 385 of the track system 302 for illuminating, for example, the cassettes 360, transport arms 370, and tracks 380. The LEDs 310 do not dissipate large amounts of heat and, therefore, mitigate risks associated with altering or heating the flammable chemicals used in the track system 302.

The system 300 includes a controller 330 that is programmed to control operation of the LEDs 310. As described above with respect to FIGS. 2 and 3, for example, the controller 330 may be programmed to selectively activate and/or deactivate one or more specific LEDs 310 based on feedback and/or sensed operating parameters of the system 302. The sensed operating parameters are based on sensor signals provided by associated sensors (e.g., sensors 192 of FIGS. 2-3). The sensors may be integrated sensors of the track system 302 and/or additional sensors provided to specifically facilitate controlling the illumination process in accordance with the present invention. The particular manner in which the controller 330 can be programmed will be readily apparent to those having ordinary skill in the art based on the description provided herein.

It also will be appreciated that the track system 302 of FIG. 4 may be integrated with a stepper system into an integrated processing system. Additional coater and/or developer units also may be incorporated into the integrated track system 302 to further increase throughput. Each unit of the integrated system may be equipped with one or more illuminating devices (LEDs) 310 in accordance with the present invention.

FIG. 5 is a flow diagram illustrating an exemplary method 400 of using an illuminating device, such as a LED, to illuminate a processing chamber of a semiconductor processing system in accordance with the present invention. The method begins at step 402 in which one or more illuminating devices are provided. In particular, the illuminating device is operatively associated with the processing chamber so as to illuminate its interior, such as according the arrangements described herein. The method proceeds to step 404.

At step 404, operating parameters of the processing system are sensed. As mentioned above, this may be implemented by sensors operatively connected with the processing chamber or other parts of the system for sensing various operating conditions and providing sensor signals indicative thereof. Next, at step 406, a determination is made (e.g., by an associated controller) as to whether the sensed parameters are within an acceptable range. If the determination is affirmative, indicating that the sensed parameters are acceptable, the method proceeds to step 408.

At step 408, another determination is made as to whether a manual activation command has been received. The manual activation command may, for example, indicate to turn the illuminating device ON or OFF, depending on its current operating condition. If the determination at step 408 is negative (no manual activation command has been received), the method returns to step 404 to sense the system operating parameters and the operating state of the illuminating device remains unchanged. For purposes of ease of explanation, the method is described as if the illuminating device is initially OFF. Because, in this example, no activation command has been received, there is no activation of the illuminating device.

If the determination at step 406 is negative (indicating that one or more sensed parameters are not acceptable) or if the determination at step 408 is affirmative (indicating receipt of a manual activation command), the method proceeds to step 410. At step 410, the operation of the illuminating device is controlled. That is, the illuminating device may be controlled (e.g., turned ON or OFF) in response to (i) receiving a manual activation command and/or (ii) sensing a parameter of the system, including the processing chamber, that is outside an expected range of values. The control at step 410 also may result in a modification of the operating condition of the illuminating device. From step 410, the method proceeds to step 412.

At step 412, operating parameters of the illuminating device are sensed. The sensing may occur whether the illuminating device is ON or OFF. As mentioned above, the sensing may be in the form of feedback received from the illuminating device itself and/or from other sensors which monitor an operating characteristic of the illuminating device. The method proceeds to step 414, in which a determination is made as to whether the sensed operating parameters of the illuminating device are within an acceptable range. If the determination is positive, indicating that the sensed parameters are within an acceptable range, the process returns to step 404. If the determination at step 414 is negative, however, indicating that one or more sensed operating parameters of the is outside an acceptable range, the method proceeds to step 416. At step 416, the control of the illuminating device is modified, such as based on its sensed operating parameters. For example, if the illuminating device is emitting too much or too little light, the intensity of light may be adjusted down or up accordingly, such as by controlling current flow through the LED. From step 416, the method returns to step 404.

While the foregoing method of using an LED to illuminate the interior of a chamber has been described as a series of steps, it is to be appreciated that the operation of the LED may be expressed by other techniques. The operation and control of the LED also may be expressed, for example, as a state diagram, in which the activation and deactivation of the LED are conditioned on the state of the manual activation command and/or the state of the various sensed parameters of the system and illuminating device. In addition, the particular order and/or number of the steps may be modified from that shown (as needed).

What has been described above are examples of the present invention. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the present invention, but one of ordinary skill in the art will recognize that many further combinations and permutations of the present invention are possible. Accordingly, the present invention is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. 

What is claimed is:
 1. A system for illuminating a semiconductor processing system, comprising: a processing chamber of the processing system having an interior; a light emitting diode associated with the chamber for illuminating the interior of the chamber; a sensor associated with the processing chamber, and operable to sense an operating condition of the processing system and to provide a sensor signal indicative of the sensed operating condition; and a controller connected to the light emitting diode via a communications link and directly coupled with the sensor to receive the sensor signal directly from the sensor, wherein the controller is operable to directly control activation of the light emitting diode via the communications link based on the sensor signal from the sensor.
 2. The system of claim 1, wherein the chamber is part of a coater unit of the processing system for providing a photoresist material onto a substrate, the light emitting diode providing light at a wavelength so as not to expose the photoresist material.
 3. The system of claim 1, wherein the chamber is part of a developer unit of the processing system for developing photoresist material applied to a substrate.
 4. The system of claim 1, wherein the processing chamber is enclosed.
 5. A system for illuminating a semiconductor processing system, comprising: a processing chamber of the processing system having an interior; a light emitting diode associated with the chamber for illuminating the interior of the chamber; a sensor associated with the processing chamber, and operable to sense an operating condition of the processing system and communicate an indication of the sensed operating condition; and a controller adapted to selectively control activation of the light emitting diode based on the indication from the sensor; wherein the processing chamber further comprises a wafer chuck having a pedestal associated therewith upon which a wafer resides and a rotatable support member operable to support and rotate the wafer chuck within the processing chamber, wherein the light emitting diode is associated with a bottom portion of the processing chamber, and configured to illuminate a bottom portion of the chuck or the rotatable support member in the bottom portion of the processing chamber for visual inspection of the bottom portion of the chuck or the rotatable support member by a technician, wherein the sensor associated with the processing chamber is further operable to sense an operating condition of the bottom portion of the chuck or the rotatable support member, and wherein the controller is further adapted to selectively control activation of the light emitting diode based on the indication from the sensor.
 6. The method of claim 5, wherein the controller is operable to rapidly activate and deactivate the light emitting diode to enable a visual monitoring of chuck when rotated by the rotatable support member. 